Conductivity testing method for a sub-harness and a sub-harness manufacturing apparatus

ABSTRACT

A conductivity testing method for a sub-harness and a sub-harness manufacturing apparatus are provided, which sub-harness manufacturing apparatus includes: a pair of connecting units each having a wire connecting portion, made of metal, vertically movable so as to connect one end of one or wires composing a sub-harness to one of terminals having a sheathing clamping portion and being arranged in a wire feeding direction; and a pair of transferring devices to transfer the terminals in a direction perpendicular to the wire feeding direction so as to position each one of the terminals under each wire connecting portions, wherein a clamping punch portion to clamp the sheathing clamping portion is provided on the wire connecting portion of each of the pair of connecting units and a conductivity testing device to judge the one, having terminals on the respective ends thereof, of the wires being good or bad is arranged between the clamping punch portions of the pair of connecting units.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the invention

[0002] The present invention relates to a conductivity testing methodfor a sub-harness to be arranged on a vehicle such as motor vehicle andto a sub-harness manufacturing apparatus.

[0003] 2. Description of the Related Art

[0004] A pressure welding apparatus, which has a pair of frames with apair of pressure welding units and a pair of connector tables so thatmany kinds of sub-harnesses composing a wiring harness can beeffectively manufactured, is suggested in Japanese Patent ApplicationLaid-open No. 10-154568

[0005] The pressure welding apparatus enables a wire to bepressure-welded to a connector on one connector table, while supplyinganother connector on the other connector table. And, a sub-harness canbe collected from the other connector table.

[0006] With respect to the above prior art, however, the sub-harnesshaving been collected from the connector table is to be set on aconductivity test tool so that the conductivity can be tested throughterminals connected on the both ends. In case that conductivitydefectiveness is found, a great deal of man-hour is required for itsrepair, thereby increasing the cost.

SUMMARY OF THE INVENTION

[0007] In view of the foregoing, an object of the present invention isto provide a conductivity testing method for a sub-harness and asub-harness manufacturing apparatus, wherein a sub-harness can beefficiency manufactured and tested.

[0008] In order to achieve the above object, as a first aspect of thepresent invention, a conductivity testing method for a sub-harness in asub-harness manufacturing process using a sub-harness manufacturingapparatus, the sub-harness manufacturing apparatus comprising: a pair ofconnecting units each having a wire connecting portion, made of metal,vertically movable so as to connect one end of one of wires composing asub-harness to one of terminals having a sheathing clamping portion andbeing arranged in a wire feeding direction; and a pair of transferringmeans to transfer the terminals in a direction perpendicular to the wirefeeding direction so as to position each one of the terminals under eachwire connecting portions, wherein a clamping punch portion to clamp thesheathing clamping portion is provided on the wire connecting portion ofeach of the pair of connecting units, comprises the steps, in aconnection process of connecting both ends of the one of the wires tothe respective terminals, of: keeping one clamping punch portion havingclamped the sheathing clamping portion onto one end of the one of thewires in contact with the sheathing clamping portion; keeping the otherclamping punch portion having clamped the sheathing clamping portiononto the other end of the one of the wires in contact with the sheathingclamping portion; and testing conductivity between one and the otherclamping punch portions so as to judge the one, having the terminals onthe respective ends, of the wires being good or bad.

[0009] As a second aspect of the present invention, a sub-harnessmanufacturing apparatus comprises: a pair of connecting units eachhaving a wire connecting portion, made of metal, vertically movable soas to connect one end of one of wires composing a sub-harness to one ofterminals having a sheathing clamping portion and being arranged in awire feeding direction; and a pair of transferring means to transfer theterminals in a direction perpendicular to the wire feeding direction soas to position each one of the terminals under each wire connectingportions, wherein a clamping punch portion to clamp the sheathingclamping portion is provided on the wire connecting portion of each ofthe pair of connecting units and a conductivity testing means to judgethe one, having terminals on the respective ends thereof, of the wiresbeing good or bad is arranged between the clamping punch portions of thepair of connecting units.

[0010] As a third aspect of the present invention, in the structure withthe above second aspect, each of the pair of connecting units isprovided with a holding means to keep the clamping punch portion incontact with the sheathing clamping portion.

[0011] As a fourth aspect of the present invention, in the structurewith either one of the above first and second aspects, the sub-harnessmanufacturing apparatus further comprises: a controlling means tosynchronize a timing to clamp the sheathing clamping portion onto theone end of the one of the wires with a timing to clamp the sheathingclamping portion onto the other end of the one of the wires.

[0012] As a fifth aspect of the present invention, in the structure withany one of the above second to fourth aspects, the terminals transferredby at least one of the pair of transferring means are of pressurewelding terminals each having a pair of pressure welding edges and beingaccommodated in respective grooves provided in parallel on an insulativebody, and an wire pressure welding blade to pressure-weld one or theother end of the one of the wires is formed on the corresponding wireconnecting portion.

[0013] According to the present invention with the above first aspect,each wire having the terminals and thereby forming the sub-harness istested in a manufacturing process of the sub-harness. That is, theterminal is electrically connected to the wire at each connecting unit,the wire connecting portion is kept in contact with the terminal in astate of the wire connecting portion having clamped the sheathingclamping portion, and the conductivity between the clamping punchportions of the respective wire connecting portions is checked. That is,a circuit (i.e. one clamping punch portion—one sheathing clampingportion—wire—the other sheathing clamping portion—the other clampingpunch portion) for the conductivity test is formed, whereby each wirehaving the terminals and composing the sub-harness is tested.

[0014] According to the present invention with the above second aspect,since the conductivity testing means is arranged between the clampingpunch portions of the respective wire connecting portions of the pair ofconnecting units, each wire having the terminals and composing thesub-harness can be tested. And, the circuit for the conductivity test isformed by making the clamping punch portions contact with the respectivesheathing clamping portions of the wire. By this, each wire having theterminals and composing the sub-harness can be tested by means of theconductivity testing means.

[0015] According to the present invention with the above third aspect,since the wire connecting portion can hold the terminal in a state ofthe sheathing clamping portion being clamped, while keeping in contactwith the sheathing clamping portion, even if there is a timing gap ofthe operation between the wire connecting portions of the pair ofconnecting units, either one of the wire connecting portions can waitfor the other, while keeping in contact with the sheathing clampingportion of the terminal.

[0016] According to the present invention with the above fourth aspect,the sheathing clamping portions to be connected to the respective endsof the wire can be clamped simultaneously. Therefore, the test can becarried out simultaneously with the clamping of the sheathing clampingportions.

[0017] According to the present invention with the above fifth aspect,at least one connecting unit of the pair of connecting units can be usedas a pressure welding unit.

[0018] The above and other objects and features of the present inventionwill become more apparent from the following description taken inconjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019]FIG. 1 is a schematic diagram showing an embodiment of asub-harness manufacturing apparatus in accordance with the presentinvention;

[0020]FIG. 2 is a plan view of the pressure welding apparatus;

[0021]FIG. 3 is a front view of the pressure welding apparatus;

[0022]FIG. 4 is a side view of the pressure welding apparatus;

[0023] FIGS. 5A-5C are front views showing a manufacture process of thesub-harness: FIG. 5A is a front view of the pressure welding apparatusat an initial state; FIG. 5B is a front view of the pressure weldingapparatus in a state of carrying out the pressure welding for theconnector table of right stage; and FIG. 5C is a front view of thepressure welding apparatus in a state of carrying out the pressurewelding for the connector table of left stage;

[0024] FIGS. 6A-6B are plan views of the sub-harness: FIG. 6A is a planview of the sub-harness manufactured on the left stage; and FIG. 6B is aplan view of the sub-harness manufactured on the right stage;

[0025]FIG. 7 is a side view of the pressure welding unit of the pressurewelding apparatus;

[0026]FIG. 8 is a plan view of the pressure welding unit;

[0027]FIG. 9 is a front view of the pressure welding unit;

[0028] FIGS. 10A-10C are front views showing movement of a rotary plateand a slider of the pressure welding unit: FIG. 10A is a front viewshowing a state of the slider being positioned at the top dead point;FIG. 10B is a front view showing a state of the slider being positionedin the middle of the top and bottom dead points; and FIG. 10C is a frontview showing a state of the slider being positioned at the bottom deadpoint;

[0029]FIG. 11 is a partly sectional side view of a wire pusher and awire receiver of the pressure welding unit; and

[0030]FIG. 12 is a side view of the pressure welding unit showing astate of the wire having been pressure-welded to the connector from thestate of FIG. 11.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

[0031] An embodiment of the present invention will now be described infurther detail with reference to the accompanying drawings.

[0032]FIG. 1 is a schematic diagram showing an embodiment of asub-harness manufacturing apparatus in accordance with the presentinvention. FIG. 2 is a plan view of the pressure welding apparatus. FIG.3 is a front view of the pressure welding apparatus. And, FIG. 4 is aside view of the pressure welding apparatus.

[0033] In FIG. 1, reference character 1 designates a pressure weldingapparatus as an example of the sub-harness manufacturing apparatus. Thepressure welding apparatus 1 has a pair of pressure welding units 2, 3(connecting units). The pressure welding apparatus 1 may be called arandom pressure welding unit. The pressure welding unit 2 is providedwith a wire connecting portion 6 vertically-movably in an allow Pdirection (i.e. up and down direction) to pressure-weld one end of thesupplied wire 4 to a pressure welding terminal 5 having a pair ofpressure welding edges. And, the pressure welding unit 3 is providedwith a wire connecting portion 7 vertically-movably in an allow Qdirection (i.e. up and down direction) to pressure-weld the other end ofthe supplied wire 4 to the pressure welding terminal 5. The wireconnecting portions 6, 7 are made of conductive metal.

[0034] The wire 4 is one of a plurality of wires composing thesub-harness. Both ends of the wire 4 are pressure-weld to the respectivepressure welding terminals 5 by means of the pressure welding units 2,3. And, upon the secure connection, a conductivity testing portion 8 (aconductivity testing means) to test or examine good or bad of theconnection makes a lamp 9 turn on. On the contrary, in case ofconductivity defectiveness, a later-described non-shown controllingportion, for example, raises an alarm instead of turning on the lamp 9.

[0035] The conductivity testing portion 8 has test circuits 10 connectedto the respective wire connecting portions 6, 7 by an appropriate means.On connecting (i.e. by pressure-welding and clamped) the wire 4 to thepressure welding terminals 5, the circuit formed of the wire connectingportion 6, the pressure welding terminal 5, the wire 4, the pressurewelding terminal 5, the wire connecting portion 7, and the conductivitytesting portion 8 is closed, and the lamp 9 turns of when the connectionis good.

[0036] The pressure welding apparatus 1 in accordance with the presentinvention features the conductivity testing portion 8 as a conductivitytesting means, which enables the wire 4 composing the sub-harness to betested in the manufacture process of the sub-harness.

[0037] Referring to FIGS. 2-4, the structure of the pressure weldingapparatus 1 is described in more detail.

[0038] As in FIG. 2 or FIG. 3, the pressure welding apparatus 1 has apair of frames 11, 12, the pressure welding unit 2 arranged in thegeneral center of the frame 11, and the pressure welding unit 3 arrangedin the general center of the frame 12. Here, the frame 11 is arranged infront of an operator, and the frame 12 is arranged behind the operator.The frames 11, 12 are arranged symmetrically with each other andperpendicularly to the wire feeding direction (an allow R direction).The pressure welding units 2, 3 are arranged in the wire feedingdirection (the allow R direction).

[0039] The frame 11 is formed laterally long and horizontally. A guiderail 13 is arranged on the frame 11 along it. The guide rail 13 isprovided with a right and left pair of connector tables 14, 15 slidablywith ML guides 16. Referring to FIG. 2, the frame has right and leftstages (Reference numerals are not designated). In an initial state, theconnector table 14 is arranged on the above left stage, and theconnector table 15 is arranged on the above right stage.

[0040] The connector tables 14, 15 are arranged on respective sides ofthe frame 11, while connector tables 14, 15 can be fixed by means ofrespective fixing cylinders 17, 18. And, the connector tables 14, 15 canbe transferred just under the pressure welding unit 2 by means of amoving cylinder 19. The fixing cylinders 17, 18 are of air type, forexample, and can be changed to an appropriate fixing means. Also, themoving cylinder 19 is of air type and can be changed to an appropriatetransferring means. The moving cylinder 19 corresponds to a transferringmeans in Claims. The transferring means may be defined as the wholestructure of the frame 11. This is the same as for the frame 12.

[0041] The connector tables 14, 15 are formed in the same size. And,connector holding bars 20 are arranged on the respective connectortables 14, 15. A plurality of (for example five, but not limitedthereto) connectors 21 are arranged on the connector holding bar 20 inparallel. The connector 21 has a plurality of pressure welding terminals5 (FIG. 1) and an electrical insulator (i.e. a connector housing, whosereference character being omitted) to parallelly-arrange these.

[0042] The connector tables 14, 15 each have a frame portion 22consisting of a plurality of rectangular pillars on both ends thereof,and a general rectangular connector holding bar 20 is arranged insidethe frame portion 22 attachably and detachably. The connector holdingbar 20 is disclosed in Japanese Patent Application Laid-open No.9-30625. Connector holders 23 corresponding to the connectors 21 invarious sizes are fixed with bolts 24 to the connector holding bar 20 inparallel detachably. The connectors 21 in desirable shapes can bearranged at random by changing position of the connector holder 23. Theconnector holders 23 have the same outside dimension, and shape of eachconnector supporting portion thereof is different according to variousform of the connectors 21. The connector holding bars 20 have the samedimension and therefore are applicable to any of the connector tables14, 15 plus later-described connector tables 37, 38 of the frame 12.

[0043] Meanwhile, a timing belt 25 is arranged on the frame 11 in alongitudinal direction thereof. And, the moving cylinder 19, is securedto the timing belt 25 through a bracket 26. The front end portion of arod 27 of the moving cylinder 19 enters an engaging hole 28 arranged inthe middle portion of the connector holding bar 20 on each of theconnector tables 14, 15 so that the connector tables 14, 15 can shiftalong the guide rail 13.

[0044] The engaging hole 28 on the connector holding bar 20 improves thepositioning accuracy of the connector 21 against the pressure weldingunit 2. This is the same for the pressure welding unit 3 on the frame12. The engaging hole 28 has a curved slideway 29 for the rod 27. Theconnector tables 14, 15 are positioned at a determined position by thefixing cylinders 17, 18, and the rod 27 of the moving cylinder 19catches the engaging hole 28 accurately.

[0045] A servomotor 30 is arranged on one end of the frame 11 so thatthe timing belt 25 can precisely move by a desirable distance throughthe timing pulleys 31. The drive of the servomotor 30 is carried outbased on position data inputted in a non-shown controlling portion inadvance. The connector tables 14, 15 are shifted or transferred from theend portions of the frame 11 to the center thereof (that is, from theabove left stage to the center, and from the above right stage to thecenter) and positioned just under the pressure welding unit 2accurately. The connector tables 14, 15 each can move when the lockingby the fixing cylinders 17, 18 are released. The fixing cylinders 17, 18are fixed to respective stays 32, and the ends of respective rods 33engage engaging holes 34 of the connector tables 14, 15. The abovemechanism is the same as later-described connector tables 37, 38.

[0046] The above non-shown controlling portion is provided in a controlunit 35 arranged, for example, on the front portion of the frame 11. Inthe control unit 35, the above conductivity testing portion 8 isprovided. The controlling portion controls a later-described variousservomotors such as the servomotor 30. On the face of the control unit35, the above lamp 9, a non-shown indicating portion, and a non-shownoperating portion, which are controlled by the controlling portion, areprovided. A so-called pilot lamp and the like are arranged on anappropriate position outside the control unit 35.

[0047] The servomotor 30 can shift the connector tables 14, 15accurately so that the wire 4 (FIG. 4) can be pressure-weld at random tothe pressure welding terminal 5 (FIG. 1) in the connector 21. The timingbelt 25 may be replaced with a ball screw.

[0048] The frame 12 has almost the same structure as the above-describedthe frame 11. The frame 12 is described similarly to the above-describedframe 11.

[0049] The frame 12 is formed laterally long, horizontally, and inparallel to the frame 11. A guide rail 36 is arranged on the frame 12along it. The guide rail 36 is provided with a right and left pair ofconnector tables 37, 38 slidably with ML guides 16. Referring to FIG. 2,the frame has right and left stages (Reference numerals are notdesignated). In an initial state, the connector table 37 is arranged onthe above left stage, and the connector table 38 is arranged on theabove right stage.

[0050] The connector tables 37, 38 are arranged on respective sides ofthe frame 12, while connector tables 37, 38 can be fixed by means ofrespective fixing cylinders 17, 18. And, the connector tables 37, 38 canbe transferred just under the pressure welding unit 3 by means of amoving cylinder 19.

[0051] The connector tables 37, 38 are formed in the same size. And,connector holding bars 20 are arranged on the respective connectortables 37, 38. A plurality of (for example five, but not limitedthereto) connectors 21 are arranged on the connector holding bar 20 inparallel. The connector tables 37, 38 each have a frame portion 22consisting of a plurality of rectangular pillars on both ends thereof,and a general rectangular connector holding bar 20 is arranged insidethe frame portion 22 attachably and detachably.

[0052] Meanwhile, a timing belt 25 is arranged on the frame 12 in alongitudinal direction thereof. And, the moving cylinder 19 is securedto the timing belt 25 through a bracket 26. The connector tables 37, 38can shift along the guide rail 36.

[0053] A servomotor 30 is arranged on one end of the frame 12 so thatthe timing belt 25 can precisely move by a desirable distance throughthe timing pulleys 31. The connector tables 37, 38 are shifted ortransferred from the end portions of the frame 12 to the center thereof(that is, from the above left stage to the center, and from the aboveright stage to the center) and positioned just under the pressurewelding unit 3 accurately.

[0054] Behind the pressure welding unit 3 of the frame 12, a scalingroller 40 is arranged. The scaling roller 40 sends forth the wire 4(FIG. 4) in the allow R direction (the above-described the wire feedingdirection). The wire 4 sent forth from the scaling roller 40 crosses theframe 12 along the wire guide 41 and, as shown in FIG. 4, reaches theframe 11 along the wire guide 43 being openable-and-closable by ahorizontal cylinder 42. That is, when the wire 4 has been sent forth bythe scaling roller 40 (FIG. 2) in a state that the connector tables (14and 37, for example) are positioned just under the respective pressurewelding units 2, 3, the front end portion of the wire 4 comes to bepositioned on the connector 21 of the connector table 14 of the frame11. And, a middle portion of the wire 4 comes to be positioned on theconnector 21 of the connector table 37 of the frame 12.

[0055] Reference character 44 designates a pushing-down member in usefor sending forth the wire 4 by a determined length by the scalingroller 40 (FIG. 2). And, reference character 45 designates apushing-down member driving cylinder. These are provided on a centertable 46. The center table 46 is connected to both the frames 11, 12with arms 47. The wire guide 43 and the pushing-down member 44 aredisclosed in Japanese Patent Application Laid-open No. 7-161437.

[0056] Over the wire 4, the above wire connecting portions 6, 7consisting of the wire pressure welding blade 48 (FIG. 1) and theclamping punch portion 49 (FIG. 1) are arranged. The clamping punchportion 49 may be formed separately from the wire pressure welding blade48. When the sliders 51 drop with the drive of the respectiveservomotors 50 of the pressure welding units 2, 3, the wire connectingportions 6, 7 are simultaneously drop by being pushed by the sliders 51,and the wire 4 is pushed down. The wire 4 is cut with cutters 52, andsimultaneously the ends of the wire 4 are pressure-welded to theconnectors 21 by the wire pressure welding blades 48 (FIG. 1).

[0057] Returning to FIG. 1, the clamping punch portion 49 clamps a pairof sheathing clamping portions 53 provided on the rear end portion ofthe pressure welding terminal 5. The wire 4 is held more tightly by thepressure welding terminal 5 through the insulative sheathing by clampingthe sheathing clamping portions 53. The circuit for the aboveconductivity test is closed with the contact of the clamping punchportion 49 and the sheathing clamping portions 53, and the lamp 9 turnson if the connection is good.

[0058] In FIG.4, the pressure welding units 2, 3 are positionedsymmetrically, and the structures are almost the same. The pressurewelding units 2, 3 are described in detail later, especially for thepressure welding unit 2.

[0059] Here, a manufacture process (a manufacture method) of thesub-harness by using the above pressure welding apparatus 1 isdescribed, referring to FIG. 5. The description is done for the pressurewelding unit 2 (taken from the pressure welding unit 3 side; the rightside in FIG. 5 corresponding to the left stage).

[0060] First, as shown in FIG. 5A, in a state that the connector tables14, 15 are positioned on both sides of the frame 11, the connectorholding bar 20 is set in the connector table 14 on the left stage.Suitable connectors 21 are arranged in advance on the connector holdingbar 20. The setting of the connectors 21 can be carried out at anotherprocess for example, wherein various shapes, for example, of connectors21 are manually or automatically mounted on various connector holdingbars 20 according to various sub-harnesses.

[0061] Next, by removing the locking by the fixing cylinder 17 (FIG. 2),as shown in FIG. 5B, the connector table 14 on the left stage shift isshifted just under the pressure welding unit 2 by driving the servomotor30 (FIG. 2) and the timing belt 25. And, the wire 4 (FIG. 4) ispressure-welded to each of the connectors 21 on the connector table 14.That is, the wire 4 (FIG. 4) is connected the corresponding the pressurewelding terminal 5 (FIG. 1) by means of the servomotor 30 (i.e. theconnection process). Meanwhile, the connector holding bar 20 is set onthe connector table 15 on the right stage. Various connectors 21 arearranged on the connector table 15 on the right stage as stated above.

[0062] After completion of pressure-welding the wires 4 (FIG. 4) to thevarious connectors 21 on the connector table 14 on the left stage, whiletesting the conductivity, as shown in FIG. 5C, the connector table 14 isreturned to the original position, and the connector table 15 is shiftedjust under the pressure welding unit 2. And, the wires 4 (FIG. 4) arepressure-welded to the connectors 21 on the connector table 15 on theright stage, while testing the conductivity, similarly to the above.Simultaneously, the connector holding bar 20 is removed from theconnector table 14 on the left stage, and another connector holding bar20 is set on the connector table 14 on the left stage.

[0063] After completion of pressure-welding the wires 4 (FIG. 4) to theconnectors 21 on the connector table 15 on the right stage, whiletesting the conductivity, as shown in FIG. 5B, the connector table 15 isreturned to the original position, and the connector table 14 is shiftedjust under the pressure welding unit 2. This operation is repeated. Bythe above, time from the connector setting to the connector removal isshortened in a great deal.

[0064] Here, as shown in FIG. 2, since two pairs of connector tables 14,15 and 37, 38 are used, two different sub-harnesses can be obtained byusing the right and left connector groups, i.e. connectors on theconnector tables 14, 37 and on the connector tables 15, 38. FIGS. 6A-6Bare plan views of the sub-harness. And, a sub-harness 56 of FIG. 6A ismanufactured by using the connector tables 14, 37 of the left stage ofthe frames 11, 12 (FIG. 2). And, a sub-harness 57 of FIG. 6B ismanufactured by using the connector tables 15, 38 of the right stage ofthe frames 11, 12 (FIG. 2). In FIG. 2, The wires 4 (FIG. 4) arepressure-welded to various connectors 21 on a state that the connectortables 14, 37 and the connector tables 15, 38 are arranged just underthe respective pressure welding units 2, 3. Here, the sub-harnesses 56,57 of FIGS. 6A, 6B differ each other in kind and arrangement of theconnectors 21 and arrangement of the wires 4 (FIG. 4). An crossingarrangement of the wires 4 (FIG. 4) can be done by shifting oneconnector table by a distance of one connector.

[0065] Meanwhile, as shown in FIG. 2, since the connector holding bars20 are arranged on the respective connector tables 14, 15, 37, 38 on theframes 11, 12 attachably and detachably, it is not necessary to changearrangement of the connectors, thereby enabling the sub-harnesses 56, 57(FIG. 6) to be manufactured quickly and securely. And, as stated above,different sub-harnesses are obtained on the respective right and leftstages of the pressure welding units 2, 3, the set production (i.e. amethod of direct manufacturing) can be done. And, for enabling the wires4 (FIG. 4) to be quickly pressure-weld to the various sizes and shapesof the connectors 21, a plurality (6 kinds, but not limited thereto) ofapplicators 58 (FIG. 7) slidably having different wire connectingportions 6 (and the wire connecting portions 7, FIG. 1) are rotatablyarranged on the present pressure welding apparatus 1. The rotatablyapplicator is disclosed in Japanese Patent Application Laid-open No.10-41041.

[0066] Next, the pressure welding unit 2 is described, referring to FIG.7. As shown in FIG. 7, the wire connecting portion 6 is fixed to a shank60. The shank 60 is provided on a rotor 61 vertically-movably. A head 62of the shank 60 engages a claw portion 63 of a slider 51 and disengageswhen the rotor 61 turns. The rotor 61 is fixed to a rotary shaft 64. Therotary shaft 64 is connected to the servomotor 68 through the timingbelt 67 and the pulleys 65, 66. The wire connecting portion 6 is guidedby a blade guide 69 (FIG. 9) which is being pushed by a spring (notshown) and is freely movable vertically.

[0067] The applicators 58 have the respective wire connecting portions 6with different sizes and shapes and the respective shanks 60 and arearranged on respective six planes (FIG. 8) of the rotor 61. Theapplicators 58 (FIG. 7) are attachable on and detachable from the rotor61 by bolts and therefore can be replaced with other ones. And, a rotarywire feeder (not shown) to feed the wires 4 (a cf. FIG. 4) of variousdiameters is arranged behind the scaling roller 40 of FIG. 2, the wire 4(FIG. 4) is changed according to kind and size of the pressure weldingterminal 5 (FIG. 1) of the connector 21, and the wire connecting portion6 meeting the wire diameter is suitably selected by means of the rotaryapplicator 58 (FIG. 7).

[0068] The slider 51 in FIG. 7 is connected to a T-like cam body 70 asshown in FIG. 9. The cam body 70 is connected to an eccentric shaft 72of a rotary plate 71 (FIG. 7). The rotary plate 71 (FIG. 7) is connectedto a rotary shaft 74 of a deceleration portion 73 of the servomotor 50as shown in FIG. 7. In FIG. 9, the eccentric shaft 72 engages ahorizontal groove 75 of the cam body 70 through the slider 76horizontally slidably. While turning the rotor 61 (FIG. 7) by rotationof the servomotor 50 (FIG. 7), the eccentric shaft 72 shifts in thehorizontal groove 75 of the cam body 70, whereby the cam body 70 goes upand down along with the slider 51. The slider 51 shifts vertically alonga guide 77.

[0069] The rotary plate 71 (FIG. 7) can turn in a range of 0-360degrees. And, as shown in FIGS. 10A-10C, the slider 51 drops down to thebottom dead point (FIG. 10C) with the turning of 0-180 degrees andclimbs up to the top dead point (FIG. 10A) with the turning of 180-360degrees. As stated above, the slider 51 and the wire connecting portion6 (FIG. 7) go up and down integrally. The next stroke of the slider 51is obtained by reversely turning the rotary plate 71 by the servomotor50 (FIG. 7).

[0070] By using the above up and down mechanism, various connectors withvarious pressure welding stroke (i.e. pressure welding height) can beapplied. That is, the stroke of the wire connecting portion 6 (FIG. 7)can be freely changed by changing the rotation angle of the rotary plate71. For example, when the rotary plate 71 of FIG. 10B is turned by 90degrees and reversely turned, the stroke of the slider 51, namely thewire connecting portion 6 (FIG. 7), is ½ of the case of 180 degrees(FIG. 10C). Accordingly, it is not necessary to change arrangement ofthe connectors, thereby enabling the sub-harnesses to be manufacturedquickly and securely.

[0071] By controlling the rotation of the servomotor 50 (FIG. 7) by anon-shown controlling portion, the wire connecting portion 6 (FIG. 7)can be kept in contact with the sheathing clamping portion 53 (FIG. 1)of the pressure welding terminal 5 (FIG. 1) until the completion of theconductivity test. That is, even if there is a gap of operation betweenthe pressure welding units 2, 3, an upward movement of the wireconnecting portion 6 (FIG. 7) can be kept waiting, while keeping incontact with the sheathing clamping portion 53 (the same is applied tothe pressure welding unit 3). The servomotor 50 (FIG. 7) corresponds tothe holding means in Claim(s). Here, if the servomotor 50 (FIG. 7) iscontrolled by the non-shown controlling portion so that the sheathingclamping portions 53 (FIG. 1) can be simultaneously clamped by therespective pressure welding units 2, 3, the manufacture time can beshortened. The non-shown controlling portion corresponds to thecontrolling means in Claim(s).

[0072] In FIG. 4, groove portions 81 of wire pushers 80 engagerespective claw portions 79 of the sliders 51 of the pressure weldingunits 2, 3, which wire pushers 80 are vertically arranged between thewire connecting portions 6, 7. The wire pushers 80 are supported byholders 82 vertically slidably. And, as shown in FIG. 11 (only thepressure welding unit 3 side is described hereinafter), a wire pusherend 83 of each pusher 80 is positioned closely over the wire 4.

[0073] And, a wire receiver 84 is arranged just closely under the wire 4and opposite the bottom of the wire pusher 80. The wire receiver 84 isfixed to the end of a vertical rod 86 of an air cylinder 85 and isvertically movable along with the movement of the rod 86. The aircylinder 85 is fixed to the frame 12 (FIG. 4) positions the wirereceiver 84 just under the wire 4 in the most extended state of the rod86. The wire pusher 80 and the wire receiver 84 are formed in arod-like, blade-like, or block-like shape, for example.

[0074] When the wire pusher 80 drops along with the wire connectingportion 7, the wire 4 is cut with the edge portion (upper edge) 87 ofthe wire connecting portion 7 and the cutter (lower edge) 52. And,simultaneously, as shown in FIG. 12, the wire 4 is tightly put betweenthe wire pusher 80 and the wire receiver 84 positioned just under thewire 4. And, also simultaneous, the air cylinder 85 is decompressedsupports the wire 4 as a weak spring. Otherwise, the air cylinder 85with a weaker pressure than the force by the wire pusher 80 may be usedso that the wire receiver 84 can be lowered by the wire pusher 80.

[0075] The wire receiver 84 can rise up to a position just under thewire 4 from a state of FIG. 11. The wire 4 is axially fixed straight bythe cutter 52 (FIG. 11), the wire pusher 80, and the wire receiver 84.

[0076] And, the wire 4 drops integrally with the wire connecting portion7 in a state being held between the wire pusher 80 the wire receiver 84and is securely pressure-welded to a corresponding pressure weldingterminal 5 (FIG. 11) of the connector 21 by means of the wire connectingportion 7. After the pressure welding (namely, after the conductivitytest), only the wire connecting portion 7 and the wire pusher 80 go up,and the air cylinder 85 is completely decompressed drops so that thewire 4 is not pushed up by the wire receiver 84. When the wire 4 hasseparated from the wire receiver 84 by the horizontal movement of theconnector table 37 (or the connector table 38), the wire receiver 84starts rising as shown in FIG. 11.

[0077] As described above, since the conductivity testing portion 8 isarranged between the wire connecting portions 6, 7 (i.e. the clampingpunch portions 49), each wire 4 with the pressure welding terminals 5 toform the sub-harnesses 56, 57 can be tested. Therefore, thesub-harnesses 56, 57 can be manufactured, while being effectivelytested. And, the cost can be reduced.

[0078] Tough the conductivity testing method for the sub-harness and thesub-harness manufacturing apparatus are described for the pressurewelding apparatus hereinabove, the method and apparatus is applicable tothe following. That is, since the above-described test can be applied toa terminal having a sheathing clamping portion, the testing method canbe applied after a sub-harness has been manufactured by an apparatuswhich can pressure-weld a terminal to at least one end of a wire.

[0079] Although the present invention has been fully described by way ofexamples with reference to the accompanying drawings, it is to be notedthat various changes and modifications will be apparent to those skilledin the art. Therefore, unless otherwise such changes and modificationsdepart from the scope of the present invention, they should be construedas being included therein.

What is claimed is:
 1. A sub-harness manufacturing apparatus,comprising: a pair of connecting units each having a wire connectingportion, made of metal, vertically movable so as to connect one end ofone of wires composing a sub-harness to one of terminals having asheathing clamping portion and being arranged in a wire feedingdirection; and a pair of transferring means to transfer the terminals ina direction perpendicular to the wire feeding direction so as toposition each one of the terminals under each wire connection portions,wherein a clamping punch portion to clamp the sheathing clamping portionis provided on the wire connecting portion of each of the pair ofconnecting units, and a conductivity testing means to judge the one,having terminals on the respective ends thereof, of the wires being goodor bad is arranged between the clamping punch portions of the pair ofconnecting units.
 2. The sub-harness manufacturing apparatus as setforth in claim 1, wherein each of the pair of connecting units isprovided with a holding means to keep the clamping punch portion incontact with the sheathing clamping portion.
 3. The sub-harnessmanufacturing apparatus as set forth in claim 1, further comprising: acontrolling means to synchronize a timing to clamp the sheathingclamping portion onto the one end of the one of the wires with a timingto clamp the sheathing clamping portion onto the other end of the one ofthe wires.
 4. The sub-harness manufacturing apparatus as set forth inclaim 2, further comprising: a controlling means to synchronize a timingto clamp the sheathing clamping portion onto the one end of the one ofthe wires with a timing to clamp the sheathing clamping portion onto theother end of the one of the wires.
 5. The sub-harness manufacturingapparatus as set forth in claim 1, wherein the terminals transferred byat least one of the pair of transferring means are of pressure weldingterminals each having a pair of pressure welding edges and beingaccommodated in respective grooves provided in parallel on an insulativebody, and a wire pressure welding blade to pressure-weld one or theother end of the one of the wires is formed on the corresponding wireconnecting portion.
 6. The sub-harness manufacturing apparatus as setforth in claim 2, wherein the terminals transferred by at least one ofthe pair of transferring means are of pressure welding terminals eachhaving a pair of pressure welding edges and being accommodated inrespective grooves provided in parallel on an insulative body, and awire pressure welding blade to pressure-weld one or the other end of theone of the wires is formed on the corresponding wire connecting portion.7. The sub-harness manufacturing apparatus as set forth in claim 3,wherein the terminals transferred by at least one of the pair oftransferring means are of pressure welding terminals each having a pairof pressure welding edges and being accommodated in respective groovesprovided in parallel on an insulative body, and a wire pressure weldingblade to pressure-weld one or the other end of the one of the wires isformed on the corresponding wire connecting portion.
 8. The sub-harnessmanufacturing apparatus as set forth in claim 4, wherein the terminalstransferred by at least one of the pair of transferring means are ofpressure welding terminals each having a pair of pressure welding edgesand being accommodated in respective grooves provided in parallel on aninsulative body, and a wire pressure welding blade to pressure-weld oneor the other end of the one of the wires is formed on the correspondingwire connecting portion.